Clicking/Grinding while accelerating, 2003 Ford Windstar

September 19, 2015 1:29 PM

I have a 2003 Ford Windstar (FWD, automatic) that after a trip up a switch backed mountain road has started making a clicking/grinding noise. The noise seems to come from front left, and only happens when stepping on the gas pretty good. For example, accelerating up grades, or trying to merge into traffic. In extreme cases, accompanying the clicking is some loss of acceleration, and a little bit of forward/back shuddering. Does not seem tied directly to RPMs, or any specific gear. How can I confirm what's broken?

I’ve checked the CV boots, and they all appear to be fine. However in the process, I discovered that the outer tie rod boots are gone, as are boots on both ends of the torsion bars, on both sides. In addition, I think I have some shot motor mounts. Mentioning in case it may be related.

Current plan is to buy parts, and do all the work myself, replacing the parts with worn out and missing boots in the process.

Do these symptoms match with a particular part going bad? Is there a way to diagnose / confirm what part(s) are causing the issues before replacement?

Thanks much!

posted by Real.Wolf to Travel & Transportation (4 answers total)

Well, it sounds initially like a CV joint, but the the fact that there is some loss of accel was scaring me, but it is possible that the engine mounts being shot is causing the engine to be bounced when reacting to the CV's kicking up a fuss when trying to get power down.

To confirm it:
Pull back the boots on the CV joints (inboard end is my suspicion, but check both) and look at them. If the grease looks nasty, likely the joint is pooched. Getting a remanufactured half shaft is often the most cost effective/easiest way to change them out, especially if both ends are shot.

That'd be my first port of call, but get those engine mounts sorted soon as if they fail properly they will take other things with them.
posted by Brockles at 1:38 PM on September 19, 2015 [1 favorite]

In my experience, bad CV joints first tend to sound off when you turn. By the time they are clicking on the straightaways, it isn't long till you'll have confirmation as the joint will fail and the vehicle will no longer move. Because I didn't see "clicking while turning" but instead clicking under hard acceleration - "steeping on the gas pretty good" I am not so sure about the CV joint diagnosis - unless the motor torquing over out of the motor mounts might be over stressing the joints. I think this may be what is happening, and it may or may not have trashed the otherwise OK CV joint.
Yes, motors will lift right out of the mount on one side under hard acceleration. BTDT.
As above, fix the motor mounts and see what the results are.
posted by rudd135 at 7:41 PM on September 19, 2015

One other note - Chrysler and Plymouth used to ( late 60's and early 70's RWD drive cars with V8 engines) put a really heavy duty steel cable between the frame and the motor right at the motor mount on the side that would lift if the mount failed. This saved my bacon (and probably my hood) at least twice.
posted by rudd135 at 7:45 PM on September 19, 2015

Clicking could be bad spark plug wires. Get a spray bottle of water (don't use a hose) and mist your spark plug wires while the vehicle is idling in park. If your engine stumbles when you mist the wires, replace them.
posted by zippy at 9:52 PM on September 19, 2015